Refractory composition



United States Patent US. Cl. 10657 5 Claims ABSTRACT OF THE DISCLOSURE Burned refractory compositions consisting essentially of 5 to 20%, by weight, zircon, 20 to 50% chrome ore, and 30 to 75% dead burned magnesite.

BACKGROUND Basic refractory compositions are those which are resistant to basic slags at elevated temperatures. On the other hand, nonbasic refractories are those that are resistant to acid slags at elevated temperatures. As a general rule, basic refractory materials and nonbasic refractory materials are not combined in the same composition. An exception to this general rule has recently been dis covered and as is described in US. Pat. No. 3,192,059 of which I am a coinventor. In that patent, a magnesitezircon composition is disclosed which is characterized by coarse textured periclase grain bonded together by forsteritic matrix, which matrix is the reaction product of an in situ solid-state reaction between periclase of the dead burned magnesite and silica of the zircon. These shapes are also characterized by spaced deposits of stabilized zirconia distributed throughout the forsteritic matrix. They are also characterized by exceptional low porosity and good resistance to cyclic temperatures as are found, for example, in glass tank regenerators.

The present invention is considered an improvement over U.S. Pat. No. 3,192,059 wherein basic compositions are provided which have increased intermediate temperature strength measured by modulus of rupture at 2300 F. and increased resistance to thermal shock as a result of having a lower modulus of elasticity and increased tensile strength.

Brick made according to the teachings of this invention should be useful in the Walls of glass tank regenerators and even in some cases in the checker structure of glass tank regenerators. Other applications of brick according to his invention will be obvious to those skilled in the refractories art.

BRIEF DESCRIPTION OF THE INVENTION According to this invention, burned basic refractory compositions are prepared from a batch consisting essentially of 50 to 20%, by weight, zircon sand, 20 to 50% chrome ore, and 30 to 75 dead burned magnesite. The zircon sand is sized to all pass 65 mesh. The chrome ore is sized to substantially all pass 14 mesh and at least 50% passes 28 mesh. The chrome ore sizing is considered critical. The magnesite is sized such that at least 20% is minus 65 mesh or ball milled fines. The rest of the magnesite is sized so that the overall sizing of the batch is from 40 to 60% plus 28 mesh, and from 40 to 60% minus 65 mesh. Basic compositions, according to this invention, are burned at temperatures in excess of 2800 F. to develop a ceramic bond. They are microscopically characterized by a coarse chrome ore and magnesite grain held by a discontinuous forsterite matrix containing dispersed stabilized zirconia deposits. Forsteritic matrix is a reaction product of an in situ solid-state reaction between the periclase of the dead burned magnesite and the silica of the zircon.

The chromite materials employed in the present invention include natural chromite or chrome ores, which can be any refractory chromite, such as Philippine, Turkish, African, including Rhodesian and the like, Grecian or other chromite ore or beneficiated chromite ore of the type ordinarily useful in refractories in this art. Refractory chrome ores preferably contain less than 6% silica.

The magnesia component of refractory compositions according to this invention is dead burned magnesite or periclase or fused magnesite as commonly used in the brickmaking art, and it preferably contains at least magnesium oxide. More refractory products and still bet ter results are obtained with higher purity periclase, especially that containing at least magnesium oxide.

Zircon is avaiable as a constituent for refractory use only as a rather fine sand or comminuted sand. Almost without exception, the present world supplies consist of sand whose largest particles will pass a 50 mesh sieve.

DETAILED DESCRIPTION Further features and other objects and advantages of this invention will become clear to those skilled in the are by a careful study of the following detailed description. In the specification and claims, all percentages and ratios and parts are by weight; chemical analyses were obtained by spectrographic analysis with control by wet chemical analysis, and are reported as oxides in accordance with the present practice of the refractories industry. All sizings are measured by Tyler series sieves.

Examples A and B TABLE I Examples A B Philippine chrome ore (percent):

28 mes 24 20 Dead burned magnes -4 10 mesh... 25 23 Ball milled fines 29 29 Zircon 600 mesh 8 8 Bulk density, p.c.f. 1 192 194 Modulus of rupture, p.s.i.:

At room temperature 2 630 730 At 2300 F 1, 340 1, 220 Apparent porosity 3 (percent)- 17. 1 16. 9 Modulus of elasticity, p.s.i. 1 94X10 2 1t 10 1 ASTM Test (313441.

ASTM Test 020-46.

4 Sonic method, see Journal American Ceramic S0c1ety, 37 (11) 1954, pages 445-457.

Examples A and B are according to the teachings of this invention. Example A is the best mode and preferred embodiment for the practice of this invention,

Examples C and D By way of comparison, Examples C and D were prepared from the batches contained in Table II, according to the teachings of my prior patent, referred to above. They were prepared in substantially the same manner as Examples A and B, except that no chrome ore addition was made to the batch. They were subjected to the same tests as Examples A and B.

The chemical analyses of the raw materials used in the exemplary mixes are given below:

T BL Percent A E II 5 Dead n Examples D Zircon Might; eiiill l Dead burned magnesite (percent): g

-3 +8 mesh 30 30 Silica (S102) 32. 3 2.8 5. smash a tlltfiliiltfi 3'3 Zircon, 600 mesh n 20 Iron Oxide (Fez 6;) u 0: 2 0rd ii 3 Bulk density, p.o.f 134 187 10 Lime (0210)"... 1.5 0.5

Modulus of rupture, p.s.i., at 2 300 F 640 900 Zirconia (Zr 2) Apparent porosity (percent) 16. 16.0 gnesia gO) 5 Modulus-of elasticity, p.s.i 14.0)(10 7.2)(10 Chromlc Oxide (OM03) 32. 7

The ball milled fines used in the exemplary mixes were Table II establishes that the chrome ore additions sursubstantleiny I F f 65 mesh prisingly increases intermediate temperature strength with- The sjclentlfic lirmclples upon which thls Invention out also increasing modulus of elasticity as would be ex- 3 ehnot enmely understo9d For example the addl' pected. As a matter of fact, modulus of elasticity is contig i g 23 3 3 2; 6 22 ;22 23 g a i t f fif t fig slderably decreased by the chlome ore addmon' modulus of elasticity of the brick; however, it would also Example E be expected to reduce the tensile strength at elevated tem- Also by Way of comparison, Example E was prepared peratures for the same reason. Nevertheless, brick accord- Without Zircon from the batch given in Table In in a mg to this inventlon have increased hot tens1le strength manner very similar to Examples A and B. The results of 25 and deqeased moduli of BIaSUFItY- testing brick made according to Example E are given in HaYmg thus: descffllbed the mventlon m detafla with Table sufficient particularity as to enable those skilled in the TABLE III art to practice it, what is desired to have protected by Phi ippine chrome ore 14 mesh 307 Leitelrs Patent is set forth in the following claims.

Dead burned 1. Burned basic refractory brick consisting essentially 4 +10 mesh, of 5 to 20%, by weight, zircon sand, 20 to 50%, by weight, 10 mesh, 8 chrome ore, 30 to 75%, by weight, dead burned magnesite, Ba11m11 1edfineS 27 said zircon all passing 65 mesh, said chrome ore sub- Bulk denslty: P w 184 o stantially all passing 14 mesh and at least 50% passing 28 Modulus of ruplturer P- at 2300 410 a mesh, said magnesite is sized such that the overall batch Apparent Poroslty 195% comprises from to 60%, by weight, plus 28 mesh,

Table III shows that the addition of zircon to composifrom 40 t0 y Weight, minus 65 meshtions according to this invention considerably increases Bufned bl'lck according to Claim 1 which are microthe intermediate temperature strength. This is somewhat 40 scopically Characterized y Chrome Ore and magnefiite Surprising h considering h h microstructure f grams held by discontinuous forsterite matrix containing brick according to this invention is characterized by dispersed Zirconia depositschrome ore-magnesia particles held together by a discon- Bfick according to claim I yp y Compflslng 30% tinuous f t rjt matrix. chrome ore, 62% magnesite, and 8% ZlICOIl.

4. Brick according to claim 1 having a modulus of Example F rupture at 2300" F. in excess of 1000 psi. Example F was prepared in the manner similar to the 5. Method of making burned basic refractory brick foregoing examples from the batch given in Table IV. comprising:

Example F Was subjected to the same tests as Examples (1) preparing a batch consisting essentially of 5 to A and B. 20%, by weight, zircon sand, 20 to 50%, by weight,

TABLE IV chrome ore, 30 to 75%, by weight, dead burned magnesite, said zircon all passing 65 mesh, said 3? chrome ore substantially all passing 14 mesh and at ii s a least 50% passing 28 mesh, s aid magnesite sized such D ea d Burned magnesite that the overall batch comprlses from 40 to by 4 +10 mesh 10 weight, plus 29 mesh material and from 40 to 60%, mesil 25 by weight, minus mesh material;

Ball milled fines: 19 (2) tempirmg the bath;

Zircon 600 mesh 16 (3) form ng the batch into shapes; 0

Bulk dnsitmpcfi, 60 (4) burning 581d shapes at temperatures 1n excess of Modulus of rupture, p.s.i. about 2800 2: ggg g ggg 470 References Cited Apparent porosity, 152% UNITED STATES PATENTS Modulus of elasticity, .s.i., 1.3 10 65 3,192,059 6/1965 ood 1: a1. 106 57 Example F demonstrates the critical nature of the 35309209 3/1967 Martmet ct 106 57 chrome ore sizing in the practice of this invention. It is JAMES E. POER Primary Examiner essential that the chrome ore be substantially all minus 14 mesh, and at least about 50% minus 28 mesh. Coarser U.S. C1.X.R.

chrome ore destroys the intermediate temperature strength. l06--59 

